Axminster rug



June 29 1926. A1,590,986 v fw. ci'. wYLlE, .JR x AXMAINSTER RUG Filed April s, v192e;

" ishing.

vrammed June 29, 192e.

PATENT o Fica.

WALKER GILL WYLIENTR., OF RED BANK, NEW JERSEY.

AxM'INsTER RUG. l l Application med April 3, 1926. serial No.' 99,485.

The presentinvention relates to AX- minster rug making and the like and aims to provide certain improvements therein.

In the manufacture of AXminst-er rugs, carpets and the like. three distinct steps are involved, namely, setting, weavingfand fin- Of these steps, the setting and weaving are processes distinct from those em loyed in other forms of weaving. getting is the process which makes the design inthe rug. as well as the size and shape. It is the process that transposes the yarn from the reel spools to theloom spools. In the twenty-seven inch loom employed for rug weaving, for example, there is a) standard of 189 tufts or endsof yarn across the twenty-seven inch breadth which makes one row of tufts, hence the setting frame coni sists of a bank of 189 reel spools, the threads from which are led .forward through a"comb or reed when winding or vsetting a loom spool.

In the weaving processthe spools are car- `ried by a chain movable over theloom, each loom spool furnishing the yarn to make one row of tuftsin the face or pile of the rug, where the loom spools are of the same width as the loom, the color of any particular tuft being previously determined from va master design, in accordance with which the yarn is Wound or set on the loom spools.

Heretofore, rectangular rugs only have been made. on, Axminster looms, -and Where large rugs were desired, several strips formed on a narrow loom were seamed together. In recent years, however, a demand has sprung up for seamless rugs, and mills equipped with onlyl narrow looms were.

forced to operate at either partial capacity or to.shut down completely.

p Acdording to`the present invention I proj pose t use Axminster looms and especially these narrow looms for` making rugs of any desired shape, either symmetrical or unsymmetrical, oval, circular, semi-circular, diaj stood that .the voperate in .exactly Amond-shaped or the like, this without wastage of stance is the'most costly item in rug manufacture. This I accomplish by winding or setting the loom spools` with yarn threads, the'position and number of said threads corresponding to the arrangement and number of tufts in the corresponding tuft rows and then carry out the weaving process as at present practiced.

A rug or the like as thus woven' will have and to accomplish yarn, which sub a rectangular jute and cotton base as heretofore, but the tufted body will be limited to the outline desired and controlled by the number of lthreads or ends of yarn on the various loom spools. If desired, the. untufted portion is then trimmed away and the rug finished off in any desired manner.

The

invention also includes other features .of i

novelty which will be hereinafter more fully described. v

By Way of example I haveshown an application of thev invention to the making of an oval rug, and in the accompanying drawings illustrating the same:-

Figurel shows a rug as it comesfrom the loom.

Fig. 2 shows the rug in finished form.

Fig. 3 is a transverse section taken on the line 3 3 of Fig. 2.

Fig. 4 a transverse section of a modified manner of finishing a rug. l

Figs. 5 to .11`are` elevations of the loom spools used to provide the rows of tufts corresponding to the lines 5-5 to 11-11 respectively in Fig. 1.

In practicing the present invention to make a non-rectangular or .ova-l rug A, as shown in Fig. 2, the loom spools Bare prepared by the setting process with yarn to the proper numbers of threads or ends, colors and positions of the threads in accordance with amaster design (not shown), understood that 'there will be a loom spool for each row of tufts in the rug. In Figs. 5

it being to 11 I have shown seven loom spools each with a plurality of threads of yarn wound thereon to correspond to the number of tufts for the rows in the rug A indicated by numbers similar to the figure numbers of said spools. These, together with intermediate and the other spools, are mounted on the loom chain in proper sequence, and the weaving process is then carried out without modification:4 i

In the weaving process, it-.will be underwarp chain and weft filling the same manner to prof cotton base ofthe rugas vide the jute and when weaving `a. rectangular rug having the widthv of the loom, but it is to be observed that the tufts are only a plied to the` base 1n accordance with the ou line ofllthe tufted portion of the-rug desired. Thereis, therefore, no wastage of yarn at the four corners of the rug base which are cut away in the finishing operation.

yao

l selves along the base of the tufted body and secured bv a line of stitching E, as best shown in Fig. 3. Another method is to trim away the entire untufted base and sew a tape around the edges of the rug, as best shown at F in Fig. 4. l

In winding or setting the yarn on the loom spools from the reel spools on the setting frame, the threads are first passed through the teethof a comb orpreed, the position of eachtooth-determining the position of a particular tuft in a row in the finished rug. In a twenty-seventh inch loom, for example, there are 189 tufts to a row,

hence there are 190 teeth tothe guiding comb or reed. And where the entire loom spool is to be Wound or set, the enlarged ends of the -spool serve as collars to prevent spreading of the terminal threads of yarn, as best shown lin Fig. 11 of the drawings. But where the terminal thread or threads are to be spaced from the'respective ends of the spool as shown in Figs. to 10, means for preventing such spreading may be employed.

4V'In my copending application' Serial No.

105,081, filed April`28, 1926, I have shown and described a preferred manner of accomplishing this end. i f

From the foregoing description it will be appreciated that by the present invention narrow Axminster looms can now be put to useful and profitable production, and .further, that rugs andthe like of any .arbitrary shape and desi wastage of yarn. v v While I have shown and described a preferred method of practicing myf-inventlon, it is to be understoodn that the specific details herein set forthpare merely illustrative of the workings of the invention, and that modifications of said details may be resorted to without departing from the spirit of the' invention. v

What I claim is y 1. The method of making a pile fabric or the like having a tufted body and a woven base, the area 4of the tufted body be'- ing less than that ofthe woven base upon which it is formed, upon an Axminster type loom, which comprises weaving a rectangular base and simultaneously forming said tufted body thereon in the form of tuft rows of desired width, by using loom spools having the tufting threads wound thereon, the

gn can be produced without position and number-of said threads corresponding to the arrangement and number of tufts in the corresponding tuft rows.

like having a tufted body of varying width on an Axminster type loom, which comprises weaving a rectangular rug base and simultaneously forming said tufted body thereon in the form Aof vtuft rows of different widths by using loom spools having the same number of ends of yarn as there are vtufts in their corresponding tuft rows.

3.`Thevmethod of makin -a rug or the on an Axminster type loom, which comprises Weaving a rectangular rug base and simultaneously forming said tufted body thereon by using loom spools, one terminal yarn ferent on different spools.

4. The method of making a rug or the like having a tufted body of non-rectangular form onan Axminster type loom, which comprises Weaving a rectangular base and 'simultaneously forming said tufted body f like of varying width on an lAXminster loom,

which comprises weaving the rug basel of greater area than the tufted rug body, trim- 2. The method of making a rug or the like having a tufted body o varying width thread of which is spaced from its respective end of the spool, said spacing being difming away the excess of the untufted rug` Ease and finishingy ofi' the raw edges of the ase.

6. The method ofmaking a rug or the like of varying width on an Axminster loom, which comprises weaving the rug base -of greater 'area than theC tufted rug body, trimming away the excess of the untufted rug base along lines substantially parallel to the tufted body but spaced therefrom, and

finishing off the raw edges of the base by bending them back upon themselves along the edges of the tufted body and securing said bent back port-ions in place.

, '7. An intermediate product 1n the making of anV Axminster rug which compr1ses a woven rectangular base `having a tufted body portion thereon of varying width, the

tufted b'ody portion lbeing adapted to constitutethe face of the rug.

In witness whereof, I have hereunto signed my name.

WALKER G ILLIWYLIE, JR. 

